BMW 528i 1985 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 528i Year: 1985 Chassis Code: E28 Market: North America (implied by model name and year, likely also applicable to European markets) 👋 Introduction Market Position Segment: Executive/Luxury Sedan Philosophy: BMW's 'Ultimate Driving Machine' ethos, emphasizing performance, comfort, and advanced engineering for its era. Competitive Analysis Key Competitors: Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6, Volvo 700 series. Key Features Engineering: Inline-six engine, rear-wheel drive, sophisticated independent suspension, focus on driver engagement and build quality. Technology For Era: Optional ABS, advanced fuel injection (Motronic), power steering, comfortable interior appointments. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for the 1985 BMW 528i (E28 chassis) Secondary Coverage: May include applicable sections for other E28 models with similar drivetrain components (e.g., 528e, 535i) Page Count Estimated Page Count: Likely between 500-1000 pages, typical for a comprehensive factory-level workshop manual of this era. Manual Type Type: Service Repair Workshop Manual Language Language: English (assumed for North American market documentation) Format Format: Digital (PDF) or Printed 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, timing, lubrication, cooling system, fuel delivery (Bosch L-Jetronic/Motronic), exhaust system. Engine Electrical: Ignition system (breakerless electronic), starter motor, alternator, engine control unit (ECU) diagnostics, sensors, wiring diagrams. Transmission: Manual transmission (Getrag 260), automatic transmission (ZF 4HP22), clutch system, driveline, universal joints, driveshaft. Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System) diagnostics and repair, brake lines, master cylinder, parking brake. Suspension: Front MacPherson struts, rear semi-trailing arms, shock absorbers, springs, control arms, anti-roll bars, steering linkage, power steering system. Steering: Recirculating ball steering gearbox, power steering pump and lines, steering column, alignment specifications. Electrical System: Battery, charging system, starting system, lighting (headlights, taillights, interior), fuses, relays, instrumentation, wipers, horn. HVAC: Heating, ventilation, and air conditioning system components, refrigerant charging, diagnostics. Body And Trim: Body panel removal and installation, interior trim, door mechanisms, window regulators, bumpers, glass replacement. Chassis And Frame: Frame structure, subframes, mounting points, corrosion protection. Diagnostics: Troubleshooting charts, diagnostic procedures for various systems, common faults and solutions. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug service, fluid level checks, belt inspections, brake pad replacement. Engine Overhaul: Detailed steps for engine disassembly, component inspection, machining recommendations, and reassembly. Transmission Repair: Overhaul procedures for both manual and automatic transmissions, clutch replacement, gear synchro repair. Brake Service: Bleeding the brake system, caliper and wheel cylinder replacement, rotor and pad replacement, ABS component testing. Suspension And Steering Repair: Replacement of shock absorbers, control arms, tie rods, ball joints, power steering pump and rack. Electrical Diagnostics: Wiring harness tracing, component testing using multimeters, troubleshooting electrical gremlins, using wiring diagrams. Bodywork And Trim Removal: Instructions for removing and reinstalling bumpers, fenders, doors, interior panels, and trim pieces. Tune Up Procedures: Spark plug gap and type, ignition timing adjustment, idle speed control, fuel mixture adjustment (where applicable). Troubleshooting Guides: Systematic approaches to diagnosing common problems with symptoms and likely causes. Technical Depth Depth: Factory-level, comprehensive. Covers from basic routine maintenance to complete engine and transmission overhauls, including detailed electrical troubleshooting and diagnostic procedures. Detail Level: Detailed step-by-step instructions, torque specifications, clearances, special tool requirements, and diagnostic flowcharts. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format), typically with searchable text for ease of navigation. Print Quality Print Quality: High-resolution scans of original manuals, ensuring clarity of text and diagrams. Expect original black and white printing. Binding Type Binding: For printed versions: Perfect bound or comb-bound for durability in a workshop environment. Paper Type Paper Type: For printed versions: Durable, matte finish paper suitable for workshop use, resisting oil and grease smudges. ⚙️ Engine Specifications Primary Engine Engine Code: M30B34 (likely for the 528i, though closely related to M30B32 in earlier models and M30B35 in later E28s) Engine Type: SOHC Inline 6-cylinder Displacement: 3.4 liters (3430 cc) Performance Horsepower: Approximately 182 hp @ 5500 rpm (may vary slightly by market and specific engine variant) Torque: Approximately 220 lb-ft @ 3000 rpm (may vary slightly) Fuel System Induction: Bosch Motronic fuel injection (combines fuel injection and ignition control) Fuel Type: Premium Unleaded Gasoline (91+ Octane recommended) Cooling System Coolant Type: BMW Blue Coolant (or compatible ethylene glycol/water mixture, typically 50/50) Lubrication Oil Type: API SG or higher, SAE 15W-40 or 10W-40 (refer to manual for specific recommendations based on climate) Oil Capacity: Approx. 6.5 liters (6.9 US quarts) with filter change 🔧 Transmission Standard Transmission Type: Getrag 260 5-speed Manual Transmission Optional Transmission Type: ZF 4HP22 4-speed Automatic Transmission Features Clutch Type: Hydraulically actuated single-plate dry clutch (for manual transmission) Fluid Specifications Manual Transmission Fluid: API GL-4 SAE 75W-90 synthetic gear oil (or specified BMW fluid) Automatic Transmission Fluid: Dexron II (or equivalent ATF specification for ZF 4HP22) 📐 Dimensions Exterior Length: Approx. 4620 mm (181.9 in) Width: Approx. 1700...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Chassis Code:

Market:

North America (implied by model name and year, likely also applicable to European markets)

👋 Introduction

Market Position

Segment:

Executive/Luxury Sedan

Philosophy:

BMW's 'Ultimate Driving Machine' ethos, emphasizing performance, comfort, and advanced engineering for its era.

Competitive Analysis

Key Competitors:

Mercedes-Benz W124 E-Class, Audi 100/200, Jaguar XJ6, Volvo 700 series.

Key Features

Engineering:

Inline-six engine, rear-wheel drive, sophisticated independent suspension, focus on driver engagement and build quality.

Technology For Era:

Optional ABS, advanced fuel injection (Motronic), power steering, comfortable interior appointments.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for the 1985 BMW 528i (E28 chassis)

Secondary Coverage:

May include applicable sections for other E28 models with similar drivetrain components (e.g., 528e, 535i)

Page Count

Estimated Page Count:

Likely between 500-1000 pages, typical for a comprehensive factory-level workshop manual of this era.

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English (assumed for North American market documentation)

Format

Format:

Digital (PDF) or Printed

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, timing, lubrication, cooling system, fuel delivery (Bosch L-Jetronic/Motronic), exhaust system.

Engine Electrical:

Ignition system (breakerless electronic), starter motor, alternator, engine control unit (ECU) diagnostics, sensors, wiring diagrams.

Transmission:

Manual transmission (Getrag 260), automatic transmission (ZF 4HP22), clutch system, driveline, universal joints, driveshaft.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System) diagnostics and repair, brake lines, master cylinder, parking brake.

Suspension:

Front MacPherson struts, rear semi-trailing arms, shock absorbers, springs, control arms, anti-roll bars, steering linkage, power steering system.

Steering:

Recirculating ball steering gearbox, power steering pump and lines, steering column, alignment specifications.

Electrical System:

Battery, charging system, starting system, lighting (headlights, taillights, interior), fuses, relays, instrumentation, wipers, horn.

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant charging, diagnostics.

Body And Trim:

Body panel removal and installation, interior trim, door mechanisms, window regulators, bumpers, glass replacement.

Chassis And Frame:

Frame structure, subframes, mounting points, corrosion protection.

Diagnostics:

Troubleshooting charts, diagnostic procedures for various systems, common faults and solutions.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug service, fluid level checks, belt inspections, brake pad replacement.

Engine Overhaul:

Detailed steps for engine disassembly, component inspection, machining recommendations, and reassembly.

Transmission Repair:

Overhaul procedures for both manual and automatic transmissions, clutch replacement, gear synchro repair.

Brake Service:

Bleeding the brake system, caliper and wheel cylinder replacement, rotor and pad replacement, ABS component testing.

Suspension And Steering Repair:

Replacement of shock absorbers, control arms, tie rods, ball joints, power steering pump and rack.

Electrical Diagnostics:

Wiring harness tracing, component testing using multimeters, troubleshooting electrical gremlins, using wiring diagrams.

Bodywork And Trim Removal:

Instructions for removing and reinstalling bumpers, fenders, doors, interior panels, and trim pieces.

Tune Up Procedures:

Spark plug gap and type, ignition timing adjustment, idle speed control, fuel mixture adjustment (where applicable).

Troubleshooting Guides:

Systematic approaches to diagnosing common problems with symptoms and likely causes.

Technical Depth

Depth:

Factory-level, comprehensive. Covers from basic routine maintenance to complete engine and transmission overhauls, including detailed electrical troubleshooting and diagnostic procedures.

Detail Level:

Detailed step-by-step instructions, torque specifications, clearances, special tool requirements, and diagnostic flowcharts.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format), typically with searchable text for ease of navigation.

Print Quality

Print Quality:

High-resolution scans of original manuals, ensuring clarity of text and diagrams. Expect original black and white printing.

Binding Type

Binding:

For printed versions: Perfect bound or comb-bound for durability in a workshop environment.

Paper Type

Paper Type:

For printed versions: Durable, matte finish paper suitable for workshop use, resisting oil and grease smudges.

⚙️ Engine Specifications

Primary Engine

Engine Code:

M30B34 (likely for the 528i, though closely related to M30B32 in earlier models and M30B35 in later E28s)

Engine Type:

SOHC Inline 6-cylinder

Displacement:

3.4 liters (3430 cc)

Performance

Horsepower:

Approximately 182 hp @ 5500 rpm (may vary slightly by market and specific engine variant)

Torque:

Approximately 220 lb-ft @ 3000 rpm (may vary slightly)

Fuel System

Induction:

Bosch Motronic fuel injection (combines fuel injection and ignition control)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane recommended)

Cooling System

Coolant Type:

BMW Blue Coolant (or compatible ethylene glycol/water mixture, typically 50/50)

Lubrication

Oil Type:

API SG or higher, SAE 15W-40 or 10W-40 (refer to manual for specific recommendations based on climate)

Oil Capacity:

Approx. 6.5 liters (6.9 US quarts) with filter change

🔧 Transmission

Standard

Transmission Type:

Getrag 260 5-speed Manual Transmission

Optional

Transmission Type:

ZF 4HP22 4-speed Automatic Transmission

Features

Clutch Type:

Hydraulically actuated single-plate dry clutch (for manual transmission)

Fluid Specifications

Manual Transmission Fluid:

API GL-4 SAE 75W-90 synthetic gear oil (or specified BMW fluid)

Automatic Transmission Fluid:

Dexron II (or equivalent ATF specification for ZF 4HP22)

📐 Dimensions

Exterior

Length:

Approx. 4620 mm (181.9 in)

Width:

Approx. 1700 mm (66.9 in)

Height:

Approx. 1410 mm (55.5 in)

Wheelbase:

Approx. 2700 mm (106.3 in)

Weights

Curb Weight:

Approx. 1450-1550 kg (3200-3400 lbs) depending on transmission and options.

Gross Vehicle Weight Rating:

Varies, consult specific vehicle VIN plate or manual.

🛡️ Safety Features

Ratings

Crash Test Data:

No standardized crash test ratings (like NHTSA/IIHS) were widely available or mandated in the same way as today. BMW historically focused on passive safety structures.

Active Features

Optional Anti-lock Braking System (ABS) available on the 528i, a significant safety feature for its time.

Traction Control:

Not typically available on the 1985 528i.

Passive Features

Airbags:

Driver airbag was optional or introduced later in the E28 lifecycle, not standard in 1985 for all models. Passenger airbags were not available.

Seatbelts:

Three-point inertia-reel seatbelts for front occupants, lap belts for rear occupants.

Body Structure:

Reinforced safety cell, crumple zones (front and rear), side-impact beams (in doors).

💡 Technology Features

Infotainment

Audio System:

Period-appropriate Blaupunkt or Becker AM/FM stereo radio with cassette player. Optional premium sound systems available.

Navigation:

Not available.

Driver Assistance

Cruise Control:

Standard or optional on most models.

On Board Computer:

Basic trip computer functions, often integrated into the instrument cluster, showing fuel consumption, range, etc.

Connectivity

Bluetooth Usb:

Not applicable for the era. Aftermarket solutions would be required.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, whichever comes first. Consult manual for precise BMW recommendations.

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for standard plugs; platinum or iridium plugs would have longer intervals if fitted aftermarket.

Coolant Flush:

Every 2 years or 30,000 miles (48,000 km).

Timing Belt Replacement:

The M30 engine uses a timing chain, not a belt, requiring no regular replacement unless worn or noisy.

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for exact BMW specification)

Power Steering Fluid:

ATF Dexron II or specified BMW fluid

Known Issues

Cooling System:

Degradation of plastic radiator tanks, water pump impeller wear, thermostat failure, aging hoses.

Fuel System:

Clogged fuel injectors, failing fuel pump, degradation of rubber fuel lines.

Electrical System:

Corrosion on electrical connectors, failing voltage regulator, aging wiring harness insulation, dashboard illumination issues.

Suspension:

Worn control arm bushings, failing rear trailing arm bushings (critical for alignment and stability), worn ball joints and tie rod ends.

Bodywork:

Rust formation, particularly in wheel wells, rocker panels, and around windows.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW has a long history of producing driver-focused, performance-oriented sedans and coupes since its inception, with a strong emphasis on engineering excellence and a reputation for reliable engines.

Model Evolution

E28 Introduction:

The E28 chassis succeeded the E12 5 Series. It was introduced in 1981 and represented a significant evolution in styling, aerodynamics, and technology, building on the foundation of its predecessor.

E28 Lifecycle:

The E28 generation was produced from 1981 to 1988. The 528i designation specifically referred to models equipped with the 2.8L or 3.2L/3.4L engines, depending on the market and year. The 1985 model year places it firmly within the mid-cycle of the E28's production.

Production

Manufacturing Locations:

Primarily Germany (Dingolfing), with potential for CKD assembly in other markets.

🏆 Awards & Recognition

Recognitions

Automotive Press:

The E28 generation, including the 528i, was widely praised by automotive journalists for its driving dynamics, refinement, and build quality, often cited as a benchmark in its class during the mid-1980s.

Ratings

Reliability Perception:

Generally perceived as a reliable and well-engineered vehicle, though maintenance is crucial due to its complex systems for the time. Early models had some early electrical issues and cooling system vulnerabilities that were refined over the E28's production run.